Aqueous dispersions for use as coatings with variable water vapor permeance ratings

ABSTRACT

Certain embodiments described herein are directed articles that include a cellulosic substrate (or a non-cellulosic substrate) and an aqueous dispersion disposed on the substrate. In certain examples, the dispersion is effective to provide a water vapor perm rating of about 2 perms or less at 25% average RH as tested by ASTM D1653, or about 2 perm or less at 25% average RH as tested by ASTM E96, when the dispersion is cured as a coating on the substrate. In some embodiments, the substrate can be (or can be part of) a building substrate such as, for example, kraft paper placed on insulation (e.g., fiberglass insulation) or oriented strand board. In some instances, the aqueous dispersion can include a plant oil macromonomer or a waterborne epoxy resin.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority under 35 U.S.C. §119(e) to U.S. PatentApplication No. 61/918,521 entitled “Aqueous Dispersion For Use AsCoatings With Variable Water Vapor Permeance Ratings,” by Kenneth D.Knapp, Kevin J. Gallagher, Murray S. Toas, Sam Yuan, Sharathkumar K.Mendon and James W. Rawlins, filed Dec. 19, 2013, which is assigned tothe current assignee hereof and incorporated herein by reference in itsentirety.

TECHNOLOGICAL FIELD

This application is related to aqueous dispersions that are effectivefor use as coatings. More particularly, certain embodiments describedherein are directed to aqueous dispersions effective to provide acoating on a substrate to have variable water vapor permeance values asa function of relative humidity (RH).

BACKGROUND

Building materials can include films or facing materials attached tothem to provide desired physical properties for insulation.

In many instances of manufacture, the facing materials used are kraftpaper with an asphalt or bituminous coating and other polymericmaterials to provide both support for the underlying fibers and toprovide a liquid water and/or water vapor retarder.

A smart vapor retarder can be used as sheeting for covering insulationmaterials installed in wall and ceiling cavities. A build-up of excessmoisture in the insulation is avoided by allowing the excess moisture toescape by vapor diffusion through the film thickness of the vaporretarder. A smart vapor retarder is a coating or film formed by amaterial, a polyamide, for example, that changes its water moisturevapor permeability in direct relationship with increases and/ordecreases of the ambient humidity conditions. This transformation allowsdrying to occur through the process of vapor diffusion, therebyimproving the speed of drying of the insulation and building materials.The film allows trapped moisture to escape, thereby alleviating aconsequent formation of mold and water damage typically resulting fromexcess trapped moisture

For example, U.S. Patent Application Publication No. 2004/0103603, whichis incorporated by reference herein, describes the attachment of a vaporretarder, such as polyamide films, to insulation or other buildingmaterials such as gypsum board, particle board, etc. This vapor retarderimparts a water vapor diffusion resistance, permeance and/ortransmission which depend on the ambient humidity.

One disadvantage of a smart vapor retarder is that the material cost maybe higher than a conventional vapor retarder. For example, a polyamidematerial cost may be approximately three times the material cost of aninexpensive water vapor retarder material, such as, polyethylene. Thehigher material cost is a disincentive for the construction industry touse a smart vapor retarder, instead of using a less costly, vaporbarrier film of polyethylene having little water vapor diffusionproperties. Accordingly, it would be advantageous for a smart vaporretarder to have a reduced material content, which would reduce thematerial cost, and serve as an incentive for the construction industryto use a smart vapor retarder. One additional disadvantage is in the useof polyethylene. Polyethylene is a commonly used vapor retarder in theinsulation industry, with a very low, but constant permeability thatdoes not allow for moisture transfer under varying levels of humidity.However, for efficient moisture transfer, heightened permeability isdesired at higher humidity.

One further disadvantage is that the precursors of coatings includechemicals that can have a detrimental environmental effect due to highamounts of volatile organic compounds (VOCs). The film or facingmaterial typically includes petroleum products, which can result insubstantial off-gassing of volatile organic compounds (VOCs) duringpreparation and/or use of the material. Other VOCs can be co-reactants,such as copolymers of sheet material such as disclosed in U.S. Pat. No.8,852,749, which discloses compositions comprising moisture barrierswith variable permeances based on compounds that are synthesized orpolymerized from highly volatile comonomers.

SUMMARY

In some aspects, the aqueous dispersions described herein can be used inplace of, or in addition to, petroleum based products. For example, theaqueous dispersions can be used to reduce the release of VOCs inmanufacturing processes as well as replace petroleum based products withthose made from renewable resources. In addition, the substantialabsence of any VOCs provides a more environmentally friendly coating. Inother aspects, the aqueous dispersion is substantially free ofpolyamide, e.g., nylon 6, whereas in other aspects, a polyamide can beincluded in the aqueous dispersions.

In one aspect, an article comprising a cellulosic substrate and anaqueous dispersion, disposed on the substrate, that is effective toprovide a water vapor perm rating as a function of RH of about 2 permsor less at 25% average RH as tested by ASTM D1653, or 1 perm or less at25% average RH tested by ASTM E96 when the aqueous dispersion is curedas a coating on the cellulosic substrate.

Both methods, ASTM D1653 and ASTM E96 use a desiccant and waterprocedure (Dry and Wet Cups) to provide a measure of the permeance. Thepermeance is measured as the time rate of water vapor transmissionthrough a unit area of flat material or construction induced by vaporpressure difference between two major surfaces of the material orconstruction under specified temperature and humidity conditions. Thepermeance is quantified in perm, wherein 1 perm is 1 grain of watervapor per hour, per square foot, per inch of mercury difference of watervapor partial pressure above and below the area. ASTM E96 is typicallyused in the insulation industry while ASTM D1653 is used for coatingssuch as paints, varnish, lacquers, etc. Results between the two methodstypically correlate when tested under similar conditions.

In some embodiments, the cellulosic substrate can be a buildingsubstrate such as, for example, kraft paper placed on insulation (e.g.,fiberglass insulation) or oriented strand board. In other embodiments,the substrate can include non-woven sheeting material, gypsum wallboard,or other building substrates.

In certain embodiments, the cured coating can be further effective toprovide a water vapor perm rating of less than or equal to 5 perms at45% average RH as tested by ASTM D1653, or less than 5 perms at 45%average RH as tested by ASTM E96. In other embodiments, the curedcoating is further effective to provide a water vapor perm rating ofabout 12 perms to about 24 perms at 75% average RH as tested by ASTMD1653, or about 6 perms to about 12 perms at 75% average RH as tested byASTM E96. In some examples, the cured coating is further effective toprovide a water vapor perm rating of greater than 25 perms at 95%average RH as tested by ASTM D1653, or greater than 17 perms at 95%average RH as tested by ASTM E96. In certain examples, the aqueousdispersion comprises a plant oil macromonomer dispersion, e.g., a seedoil macromonomer dispersion, a vegetable oil macromonomer dispersion, aseed oil macromonomer emulsion, a vegetable oil macromonomer emulsion,etc. In other embodiments, the dispersion can include a reactant addedto the aqueous dispersion. In some examples, the aqueous dispersioncomprises a plant oil macromonomer dispersion, e.g., a vegetable oilmacromonomer dispersion, and the reactant comprises a free radicallypolymerized monomer, e.g., a derivatized benzene comprising anunsaturated moiety such as, for example, styrene. In other examples, theaqueous dispersion comprises a waterborne epoxy resin dispersion and thereactant comprises an amine, e.g., an aliphatic amine or a non-aliphaticamine. In some instances, the waterborne epoxy resin dispersioncomprises a waterborne solid epoxy resin dispersion, e.g., an aqueousdispersion of the solid epoxy resin, and a nonionic surfactant. Incertain embodiments, the aqueous dispersion can include at least onefiller, a stain-resistance additive or other additives.

In another aspect, an article comprising a cellulosic substrate and aplant oil macromonomer dispersion disposed on the cellulosic substrateand effective to provide a variable water vapor perm rating, as testedby ASTM D1653 (or ASTM E96), when the plant oil macromonomer dispersionis cured as a coating on the cellulosic substrate is provided. In someembodiments, the variable water vapor perm rating as tested by ASTMD1653 is about 2 perm or less at 25% average RH, is less than or equalto 5 perms at 45% average RH, is about 12 perms to about 24 perms at 75%average RH, and is greater than 25 perms at 95% average RH; or as testedby ASTM E96 is about 2.5 perm or less at 25% average RH, is less than orequal to 5 perms at 45% average RH, is about 6 perms to about 12 permsat 75% average RH, and is greater than 11 perms at 95% average RH Insome embodiments, the dispersion can include one or more of a filler, aflame retardant, a surfactant, a stain-resistance additive, and abiocide. In certain embodiments, the cellulosic substrate can be kraftpaper, oriented strand board, gypsum wallboard, or other substrates usedin the building industry.

In an additional aspect, an article comprising a cellulosic substrateand a waterborne epoxy resin dispersion, e.g., an aqueous epoxy resindispersion, disposed on the cellulosic substrate and effective toprovide a variable water vapor perm rating, as tested by ASTM D1653 isabout 2 perm or less at 25% average RH, is less than or equal to 5 permsat 45% average RH, is about 12 perms to about 24 perms at 75% averageRH, and is greater than 25 perms at 95% average RH; or as tested by ASTME96 is about 2 perm or less at 25% average RH, is less than or equal to5 perms at 45% average RH, is about 6 perms to about 12 perms at 75%average RH, and is greater than 17 perms at 95% average RH. In someinstances, the waterborne epoxy resin is a waterborne solid epoxy resin,e.g., a waterborne solid epoxy resin comprising a diglycidyl ether ofbisphenol-A. In other embodiments, one or more reactants, fillers,surfactants, stain-resistance additives, biocide, or other additives canbe present in the dispersion. In certain embodiments, the cellulosicsubstrate can be kraft paper, oriented strand board, gypsum wallboard,or other substrates used in the building industry.

In another aspect, a method of providing a coating that has variablewater vapor perm ratings as tested by ASTM D1653 (or ASTM E96), themethod comprising disposing an aqueous dispersion on a substrate, andcuring the disposed aqueous dispersion on the substrate to provide acoating comprising a variable water vapor perm rating as tested by ASTMD1653 (or ASTM E96) is described. In some embodiments, the variablewater perm rating as tested by ASTM D1653 is about 2 perm or less at 25%average RH, is less than or equal to 5 perms at 45% average RH, is about12 perms to about 24 perms at 75% average RH, and is greater than 25perms at 95% average RH; or as tested by ASTM E96 is about 1 perm orless at 25% average RH, is less than or equal to 5 perms at 45% averageRH, is about 6 perms to about 12 perms at 75% average RH, and is greaterthan 17 perms at 95% average RH.

In certain instances, the method can include co-spraying the aqueousdispersion and a reactant on the substrate. In some embodiments, themethod can include adding a reactant to the aqueous dispersion prior todisposal of the aqueous dispersion on the substrate. In additionalembodiments, the method can include co-spraying the aqueous dispersionand a surfactant on the substrate. In some examples, the method caninclude adding a surfactant to the aqueous dispersion prior to disposalof the aqueous dispersion on the substrate. In other embodiments, themethod can include co-spraying the aqueous dispersion, a reactant and asurfactant on the substrate. In some examples, the method can includeadding a surfactant and a reactant to the aqueous dispersion prior todisposal of the aqueous dispersion on the substrate. In furtherexamples, the method can include rolling the aqueous dispersion onto thesubstrate. If desired one or more thickening agents, surfactants orother materials can be added to facilitate the rolling process. In someembodiments, the aqueous dispersion can be co-sprayed with a polyamideonto the substrate or a polyamide can be added to the dispersion priorto disposal. In certain examples, one or more biocidal agents can beadded to or co-sprayed with the aqueous dispersion.

In another aspect, a kit comprising an aqueous dispersion, a reactantand instructions for using the aqueous dispersion and the reactant isprovided. In some embodiments, the reactant is effective to mix with theaqueous dispersion to provide a cured coating on a substrate, in whichthe cured coating provides a variable water vapor perm rating as testedby ASTM D1653/E96, in which the cured coating has a water vapor permrating of about 2 perm or less at 25% average RH as tested by ASTMD1653, or less than 1 perm at 25% average RH as tested by ASTM E96 whenthe aqueous dispersion is cured as a coating on the substrate.

In certain embodiments, the aqueous dispersion and the reactant of thekit are configured for co-spraying onto the substrate. In someembodiments, the kit can include an aqueous carrier effective todisperse a vegetable oil macromonomer, a waterborne epoxy resin or both.In some instances, the kit may also include one or more of a nonionicsurfactant, a biocidal agent, a building substrate, and a sprayingdevice.

In another aspect, a method of facilitating use of a building substrateis provided. In some examples, the method comprises providing an aqueousdispersion effective to provide a cured coating on a substrate, in whichthe cured coating provides a variable water vapor perm rating as testedby ASTM D1653 (or ASTM E96), in which the cured coating has a watervapor perm rating of about 1 perm or less at 25% average RH as tested byASTM D1653 (or ASTM E96) when the aqueous dispersion is cured as acoating on the substrate, and providing instructions for using theaqueous dispersion to form the coating.

In certain embodiments, the method comprises providing a reactant foruse with the aqueous dispersion to provide the cured coating. In otherembodiments, the method comprises providing one or more of a surfactant,a biocidal agent, a filler and combinations thereof for use with thereactant and the aqueous dispersion to provide the cured coating.

In an additional aspect, a composition effective to provide a curedcoating on a substrate, in which the cured coating has a water permrating as tested by ASTM D1653 is about 2 perm or less at 25% averageRH, is less than or equal to 5 perms at 45% average RH, is about 12perms to about 24 perms at 75% average RH, and is greater than 25 permsat 95% average RH; or as tested by ASTM E96 is about 2 perm or less at25% average RH, is less than or equal to 5 perms at 45% average RH, isabout 6 perms to about 12 perms at 75% average RH, and is greater than11 perms at 95% average RH is described. In some embodiments, thecomposition comprises an aqueous dispersion, a surfactant and a reactanteffective to react with the dispersed material in the aqueous dispersionto provide the cured coating.

In certain examples, the dispersed material comprises a plant oilmacromonomer, e.g., a vegetable oil macromonomer. In other examples, thereactant is a derivatized benzene comprising an unsaturated moiety. Insome examples, the dispersed material comprises a waterborne solid epoxyresin. In further examples, the reactant is an amine, e.g., an aliphaticamine or a non-aliphatic amine. In certain embodiments, the compositioncan include one or more of a surfactant, a biocidal agent, a filler orother materials.

In other configurations, an article comprising a non-cellulosicsubstrate, and an aqueous dispersion disposed on the substrate andeffective to provide a variable water vapor perm rating as a function ofhumidity, in which the water vapor perm rating is about 2 perms or lessat 25% average RH as tested by ASTM D1653, or about 1 perm or less at25% average RH as tested by ASTM E96, when the aqueous dispersion iscured as a coating on the non-cellulosic substrate is provided.

In some aspects, an article comprising a non-cellulosic substrate, and aplant oil macromonomer dispersion disposed on the non-cellulosicsubstrate and effective to provide a variable water vapor perm rating,as tested by ASTM D1653 (or ASTM E96), when the plant oil macromonomerdispersion is cured as a coating on the non-cellulosic substrate isdescribed.

In other aspects, an article comprising a non-cellulosic substrate, anda waterborne epoxy resin dispersion disposed on the non-cellulosicsubstrate and effective to provide a variable water vapor perm rating,as tested by ASTM D1653 (or ASTM E96), when the waterborne epoxy resindispersion is cured as a coating on the non-cellulosic substrate isdisclosed.

Additional features, aspects, examples and embodiments are described inmore details below.

BRIEF DESCRIPTION OF THE FIGURES

Certain embodiments are described with reference to the accompanyingfigures in which:

FIGS. 1A and 1B are articles (100) comprising a substrate (110) with acoating (120) disposed thereon or coatings (1202) and (1204) disposed onopposite surfaces;

FIG. 2 is a graph showing water vapor perm values as a function of RHfor three test compositions and a nylon 6 control; and

FIG. 3 is a graph showing water perm values for a nylon 6 control and anepoxy resin based coating.

FIGS. 4 and 5 are graphs showing water perm values for samples accordingto the present disclosure.

It will be recognized by the person of ordinary skill in the art, giventhe benefit of this disclosure, that certain dimensions or features inthe figures may have been enlarged, distorted or shown in an otherwiseunconventional or non-proportional manner to provide a moreuser-friendly version of the figures. Where dimensions or values arespecified in the description below, the dimensions or values areprovided for illustrative purposes only. Reference to front, back, topand bottom are provided for exemplary purposes and are not limiting.

DETAILED DESCRIPTION

Certain embodiments are described below with reference to singular andplural terms in order to provide a user friendly description of thetechnology disclosed herein. These terms are used for conveniencepurposes only and are not intended to limit the materials and articlesdescribed herein as including or excluding certain features unlessotherwise noted as being present in a particular embodiment describedherein.

In certain examples, the articles, compositions and methods describedherein can provide desirable attributes and physical propertiesincluding, for example, variable water vapor permeance ratings (alsoreferred to herein as variable water vapor perm ratings). Unlessotherwise noted, the water vapor permeance ratings described herein aremeasured according to ASTM D1653, dated 2013, which is also referred toas the “dry cup” method. It should be noted that ASTM E96, Procedure Acan also be used instead of ASTM D1653 to determine the water vapor permratings. ASTM D1653 and ASTM E96 are similar methodologies except thecup size used in the protocols are different. The particular testingtemperature used is specified in the method and may be, for example,15-40° C. and is typically around 21-23° C. Reference to a “variablewater vapor perm rating” refers to the change in the measured watervapor perm rating at different RH values. A lower water vapor permrating is indicative of higher resistance to water vapor flow. Forexample, in some embodiments of the articles and compositions describedherein, the water vapor perm rating desirably increases with increasingRH to permit water vapor to pass through more readily, e.g., changesfrom less than 2 perms at 25% RH to about 25 perms or more at 95% RH astested by ASTM D1653, or less than 1 perm at 25% RH to about 17 perms ormore at 95% RH as tested by ASTM E96. The variability in the water permratings need not be linear as a function of RH, and in certaininstances, the variability may be logarithmic, exponential or otherwisenon-linear over a selected RH range.

In embodiments, the permeance profiles for the foregoing cured coatingon a cellulosic substrate, the article comprising a cellulosic substrateand a plant oil macromonomer, the article comprising a cellulosicsubstrate and a waterborne epoxy, the method of providing a coatingcomposition, the cured coating provided by the kit, the method offacilitating use of a building substrate, or the cured coating obtainedfrom the composition can include any combination of the followingpermeance values.

As tested by ASTM E96, the permeance is about 2.5 perm or less at 25%average RH, such as 2.3 perm or less, 2.2 perm or less, 2.0 perm orless, 1.8 perm or less, 1.6 perm or less, 1.4 perm or less, 1.2 perm orless, 1.1 perm or less. The permeance is at least 0.02 perm at 25%average RH. The permeance can range from 0.02 perm to 2.5 perms at 25%average RH, such as from 0.5 perm to 2.4 perms, or 0.8 perm to 2.3perms.

As tested by ASTM E96, the permeance is about 5 perms or less at 45%average RH, such as 4.8 perms or less, 4.5 perms or less, 4.2 perm orless, 4.0 perms or less, 3.8 perms or less, 3.6 perms or less, 3.4 permsor less, 3.2 perms or less. The permeance is at least 1.0 perm at 45%average RH. The permeance can range from 1.0 perm to 5 perms at 45%average RH, such as from 2.0 perms to 4.5 perms, or 2.5 perms to 4.0perms. In at least one embodiment, the difference between the permeanceat 45% average RH and 25% average RH is at least 0.5 perm, such as atleast 0.8 perm, at least 1.0 perm, at least 1.1 perms, or at least 1.2perms.

As tested by ASTM E96, the permeance is at least 5.5 perms at 75%average RH, such as at least 5.7 perms, at least 6.0 perms, at least 6.5perms, at least 7.0 perms, at least 7.3 perms, at least 7.5 perms, atleast 7.8 perms, or at least 8.0 perms. The permeance is not greaterthan 12.0 perms at 75% average RH, such as not greater than 11.5 perms,not greater than 11.0 perms, not greater than 10.5 perms, not greaterthan 10.0 perms, not greater than 9.5 perms, not greater than 9.0 perms,or not greater than 8.5 perms. The permeance can range from 6.0 perms to12.0 perms at 75% average RH, such as from 6.5 perms to 10.5 perms, or7.0 perms to 9.0 perms at 75% average RH. In at least one embodiment,the difference between the permeance at 75% average RH and 45% averageRH is at least 2 perms, such as at least 3 perms, at least 3.5 perms, atleast 3.7 perms, or at least 4 perms. In at least one embodiment, thedifference between the permeance at 75% average RH and 25% average RH isat least 3 perms, such as at least 4 perms, at least 4.5 perms, at least4.7 perms, or at least 5 perms.

As tested by ASTM E96, the permeance is at least 11 perms at 95% averageRH, such as at least 12.0 perms, at least 15.0 perms, at least 20.0perms, at least 21.0 perms, at least 22.0 perms, at least 23.0 perms, atleast 25.0 perms, or at least 30.0 perms. The permeance is not greaterthan 55.0 perms at 95% average RH. The permeance can range from 11.0perms to 55.0 perms at 95% average RH, such as from 25 perms to 54perms, or 30 perms to 53 perms at 95% average RH. In at least oneembodiment, the difference between the permeance at 95% average RH and75% average RH is at least 3 perms, such as at least 5 perms, at least10 perms, at least 15 perms, or at least 20 perms. In at least oneembodiment, the difference between the permeance at 95% average RH and45% average RH is at least 6 perms, such as at least 10 perms, at least20 perms, at least 22 perms, or at least 25 perms.

The permeance profiles of the cured coatings are non-linear across therange of the average relative humidity. In at least one embodiment, astested by ASTM E96, the permeance is between 1 perm and 2.5 perms at 25%average RH, between 3.0 perms and 4.0 perms at 45% average RH, between7.0 perm and 15.0 perms at 75% average RH.

In some examples, the articles described herein can include a coatingthat is substantially free of polyamides but has water vapor permratings similar to those commonly provided by a coating comprisingpolyamides, e.g., nylon 6, on a substrate. For example, the article caninclude a cured coating that has substantially the same perm ratings asa function of humidity as the perm ratings provided by a coatingcomprising a polyamide such as nylon 6 even though the instant coatingsmay be substantially free of polyamides. In some embodiments, thesubstantially free polyamide coating may have perm ratings within about15-25% of the perm rating of a coating comprising nylon 6 at 25% averageRH, within about 15-20% of the perm rating of a coating comprising nylon6 at 45% average RH, within about 15-20% of the perm rating of a coatingcomprising nylon 6 at about 75% average RH and within about 15-20% ofthe perm rating of a coating comprising nylon 6 at 95% average humidity.

In some embodiments, the coatings provided herein can be present on acellulosic substrate that is part of a building material such as, forexample, kraft paper coated fiberglass insulation, oriented strandboard, gypsum wallboard, or other materials commonly used in thebuilding industry that permit water vapor to enter or exit a buildingstructure. In another embodiment, the substrate can be a woven or anon-woven material. In certain embodiments, the articles describedherein can include a composition comprising an aqueous dispersion ofmaterial that can be disposed and/or cured on a surface of a substrateto provide desirable water vapor perm ratings at different RH values. Incertain examples, suitable materials for dispersal include those whichdo not phase separate at a temperature of about 25-40° C. and can begenerally coated or sprayed onto a substrate in an aqueous carrier,e.g., an aqueous carrier that is not considered a strong base or astrong acid, to provide a substantially homogeneous cured coating on thesubstrate. In some examples, the aqueous dispersion may comprise solidparticles suspended in an aqueous carrier. In other examples, theaqueous dispersion may comprise an oil that is emulsified or suspendedin an aqueous carrier. As described herein, to facilitate dispersion ofa desired material in an aqueous carrier, it may be desirable to includeone or more detergents, surfactants, salts or other suitable materialsthat can assist in suspension or emulsification of the materials in theaqueous carrier. During application of the materials, the aqueouscarrier desirably is removed, e.g., through passive evaporation, activeevaporation (for example, using an air current), wicking, decanting,heating or otherwise removal of the aqueous carrier to provide a coatingwith a variable water vapor perm rating on the surface of the substrate.In some instances, the water vapor perm rating of the cured coating isabout 2 perm or less at 25% average RH as tested by ASTM D1653, or about1 perm or less at 25% average RH as tested by ASTM E96, when the aqueousdispersion is cured as a coating on the substrate. In other embodiments,the water vapor perm rating of the cured coating is less than or equalto 5.0 perms at 45% average RH as tested by ASTM D1653, or less than orequal to 2.5 perms at 45% average RH as tested by ASTM E96. Inadditional embodiments, the water vapor perm rating of the cured coatingis about 12 perms to about 24 perms at 75% average RH as tested by ASTMD1653, or about 6 to 12 perms at 75% average RH as tested by ASTM E96.In other examples, the water vapor perm rating of the cured coating isgreater than 25 perms at 95% average RH as tested by ASTM D1653, orgreater than 17 perms or less at 95% average RH as tested by ASTM E96.Where a coating displays the water vapor perm rating noted above atdifferent RH values, the change in perm rating as humidity increasesmay, as noted herein, be linear or non-linear. Where cellulosicsubstrates are used, the substrate may be a woven or non-woven substratecomprising cellulose based materials, e.g., paper or paper fibers,strands, etc. or other cellulose based materials which are present in anon-woven material or are woven together optionally with non-cellulosematerials.

In other instances, the substrate may be a non-cellulosic substrate.Non-cellulosic substrates are substrates that do not include anycellulose based materials. For example, woven and non-wovennon-cellulosic substrates may be used with the aqueous dispersionsdescribed herein. In some configurations, the non-cellulosic substratemay be comprise a woven material including one or more fabrics, Wherenon-woven cellulosic materials are used, the non-woven can be selected,for example, from a polypropylene, a polyethylene, a polystyrene, apolyester, a polyurethane, a fiberglass, a spunbond polymer, and apoint-bonded polymer. The non-woven may be a wet-laid non-woven, an airlaid non-woven or non-woven materials that can be produced using otherprocesses.

In certain examples, the aqueous dispersions described herein caninclude one or more plant oils. Illustrative plant oils include oilsextracted from seeds and oils extracted from plant structures other thanseeds. In some embodiments, the plant oil is a plant oil macromonomer.As used herein, the term macromonomer refers to a molecule that includesa terminal moiety that can function as a monomer. A single mole ofmacromonomer provides a single monomeric unit to the chain of a polymer.As described herein, a macromonomer can be polymerized and/or cured byreaction with a suitable reactant. In some instances, the plant oilmacromonomer may be a fruit oil macromonomer, a tree oil macromonomer, ashrub oil macromonomer, a herb oil macromonomer, a flower oilmacromonomer, a bush oil macromonomer, a vegetable oil macromonomer(VOMM) and combinations thereof.

In certain embodiments, the aqueous dispersion may comprise a vegetableoil macromonomer from one or more of a leaf vegetable plant, a seedvegetable plant, a fruit vegetable plant, a root vegetable plant, aflower vegetable plant, a bud vegetable plant, a flax plant andcombinations thereof. In some embodiments, the vegetable oilmacromonomer may be produced by a bean plant, a soybean plant, a carrotplant, a beet plant, a turnip plant, a radish plant or other vegetableplants. In certain embodiments, the vegetable oil macromonomer can benaturally produced, can be produced from naturally occurring materialsor may be synthetic or may be a derivative of a naturally producedvegetable oil macromonomer. For example, the VOMM may be one or more ofthose described in U.S. Pat. No. 8,450,414.

In some embodiments, the VOMM can be derivatized prior to use byreacting the naturally produced oil with one or more derivatizingagents. For example, many VOMMs (and many plant oils) include one ormore sites of unsaturation. These sites of unsaturation may beadvantageously used and/or may be consumed by auto-oxidation as thedispersion/coating dries. Derivatized forms may be particularly suitablefor emulsion copolymerization with other species to provide a coating ona substrate as described herein. In one embodiment, an unsaturated plantoil can be reacted with a primary or secondary amine followed byreaction with one or more other species to provide a monomeric formsuitable for polymerization. In one embodiment, a vegetable oil can beconverted to a fatty amide (meth)acrylate monomer by reaction withethanolamine or substituted ethanolamine (e.g., N-methyl ethanolamine,N-oleoylethanolamine, N-ethylethanolamine, N-propylethanolamine,N-butylethanolamine, N-tert-butylethanolamine,N-(tert-butoxycarbonyl)ethanolamine, N-(allyloxycarbonyl)ethanolamine,benzyl N-(2-hydroxyethyl)carbamate, ethyl-N-(2-hydroxyethyl)-carbamate,or diethanolamine) followed by reaction with either (meth)acryloylchloride or (meth)acrylic acid. For example, a plant oil such as linseedoil, soybean oil, safflower oil, tung oil and coconut oil can be reactedwith substances, e.g., (meth)acryloyl chloride or (meth)acrylic acid. Inanother embodiment, a urethane fatty amide (meth)acrylate monomer can beproduced by reaction of hydroxyethyl(meth)acrylate reacted withisophorone diisocyanate. For example, hydroxyethyl(meth)acrylate can bereacted with isophorone diisocyanate in a first reaction, e.g., thehydroxyl(meth)acrylate is reacted in equimolar proportion withisophorone diisocyanate. In a separate reaction, a plant oil, forexample, soybean oil, coconut oil, safflower oil, tung oil or linseedoil is reacted with ethanolamine (or substituted ethanolamine) to formthe hydroxyl functional fatty amide. The products of the two reactionscan be reacted to provide a urethane fatty amide (meth)acrylate monomer.

In certain embodiments, the resulting macromonomer can be suspended ordispersed in an aqueous carrier optionally with a surfactant ordetergent. Polymerization of the macromonomer can occur by the additionof a suitable reactant that can react with the reactive sites of themacromonomer to provide a dispersed polymer. While not limiting, manysuitable reactants include one or more sites of unsaturation, e.g.,comonomers with vinyl unsaturation or other sites of unsaturation.Illustrative reactants that are suitable for reaction with themacromonomers include, but are not limited to, vinyl acetate, vinylchloride, vinyl ester of a saturated tertiary branched carboxylic acid,acrylonitrile, acrylamide, 2-ethylhexyl acrylate, 2-ethylhexylmethacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethyl methacrylate,glycidyl acrylate, glycidyl methacrylate, acrylic acid, methacrylicacid, butyl acrylate, butyl methacrylate, methyl methacrylate, methylacrylate, p-acetoxystyrene, polyvinyl alcohol, ethylene vinyl alcoholand styrene or other derivatized forms of benzene that include one ormore unsaturated side chains, e.g., benzylic side chains.

In certain embodiments, a generic formula of a vegetable oilmacromonomer is shown below as formula (I)

where R is CH₃, H or CH₂CHOH, R′ is a saturated or unsaturated straightchain alkyl group of a fatty acid of a vegetable oil (e.g., a straightchain alkyl group having from about 12 to about 24 carbons with 0, 1, 2,3, 4 or 5 sites of unsaturation within the chain), R″ is CH₃ or H, and Uis CH₂CH₂, CH₂CH₂CH₂ or a group of formula (II)

In some embodiments, the group R′ may be the hydrocarbon chain fromlauric acid, myristic acid, palmitic acid, stearic acid, eleostearicacid, caprylic acid, capric acid, lignoceric acid, palmitoleic acid,oleic acid, linoleic acid, alpha-linolenic acid, or gamma-linolenicacid.

In certain embodiments, R is CH₃, R′ is a 16-18 carbon straight chainalkyl group with 1-3 vinyl groups, R″ is methyl and U is CH₂CH₂. Inother examples, R is CH₃, R′ is a 16-18 carbon straight chain alkylgroup with 1-3 vinyl groups, R″ is hydrogen and U is CH₂CH₂. In someexamples, R is CH₃, R′ is a 17 carbon straight chain alkyl group with 2vinyl groups, R″ is methyl and U is CH₂CH₂. In some examples, R is CH₃,R′ is a 17 carbon straight chain alkyl group with 2 vinyl groups, R″ ishydrogen and U is CH₂CH₂. In some examples, R is CH₃, R′ is a 17 carbonstraight chain alkyl group with 2 vinyl groups (one at carbon 8 and oneat carbon 11 as counted from the carbonyl group bonded to R′), R″ ismethyl and U is CH₂CH₂. In other examples, R is CH₃, R′ is a 17 carbonstraight chain alkyl group with 2 vinyl groups (one at carbon 8 and oneat carbon 11 as counted from the carbonyl group bonded to R′), R″ ishydrogen and U is CH₂CH₂. In yet other embodiments, a VOMM havingformula (III) (referred to below as SoyAA-1) can be used

and can be combined in an aqueous dispersion with one or more of vinylacetate, vinyl chloride, vinyl ester of a saturated tertiary branchedcarboxylic acid, acrylonitrile, acrylamide, 2-ethylhexyl acrylate,2-ethylhexyl methacrylate, 2-hydroxyethyl acrylate, 2-hydroxyethylmethacrylate, glycidyl acrylate, glycidyl methacrylate, acrylic acid,methacrylic acid, butyl acrylate, butyl methacrylate, methylmethacrylate, methyl acrylate, p-acetoxystyrene, polyvinyl alcohol,ethylene vinyl alcohol and styrene or other derivatized forms of benzenethat include one or more unsaturated side chains, e.g., benzylic sidechains. The combination of formula (III) with one or more of thesecompounds can result in polymerization, which can provide the coatingshaving the variable water vapor perm ratings described herein once thedispersions are disposed on a suitable substrate and a final coating isformed.

In other embodiments, the aqueous dispersion can include one or morewaterborne epoxy materials or resins that can polymerize to provide acoating. In some embodiments, the waterborne epoxy material can be aType I or a Type II epoxy material. Type I epoxy materials generally arelow molecular weight materials that can be cured with a reactant thatcan also function as an emulsifier. Type I epoxy resins are often basedon bisphenol A or bisphenol F and have an epoxide equivalent weight ofless than 250. Type II epoxy materials are high molecular weightmaterials that tend to be present in solid form with epoxide equivalentweights of more than 450, e.g., about 750-1500 EEWs. Type II solid epoxyresins can be dispersed at about 50-55% solids in water and typicallyare used with an emulsifier or surfactant. The reactant used with a TypeII system can diffuse into the dispersed solid particles and crosslinkthe epoxy groups. Illustrative reactants for use with Type I and Type IIepoxy resins may be those with one or more free amine groups asdiscussed herein. Illustrative commercially available waterborne epoxyresins include, but are not limited to, EPI-REZ™ epoxy waterborne resins(available from Momentive), Ancarez™555 (available from Air Products),the THW grades of waterborne epoxy resins (available from Epotec) orother commercially available epoxy resins. In certain examples, theepoxy resin can be selected such that substantially zero VOCs arepresent in the aqueous dispersion to provide the coatings describedherein with the desirable variable water vapor perm values. For example,where a Type II epoxy resin is used, glycol ether is often added to aidin processing. In the aqueous dispersions provided herein, however,glycol ether (and other VOCs) may be omitted even where a Type II epoxyresin system is implemented.

In some embodiments, the waterborne epoxy material can include a singlereactive epoxy group at one end of the molecule, e.g., can react as amacromonomer. In other embodiments, the waterborne epoxy material caninclude two or more reactive epoxy groups in the molecule. In certainexamples, the waterborne epoxy material can have a formula as shown informula (IV), or be a derivative of formula (IV)

which is generally a diglycidyl ether of bisphenol-A. In some instances,the epoxy material can be reacted with a reactant that comprises one ormore amine groups, e.g., an aliphatic amine or an aliphatic diamine,which can result in opening of the epoxy ring and coupling of the aminegroup to the epoxy material. If the amine is a diamine, a similarreaction can occur with an additional epoxy group to build up thepolymer. In addition, cross-linking may occur at the amine sites byreaction with an epoxy group. Suitable amines for use with the epoxymaterials described herein include primary aliphatic amines, secondaryaliphatic amines, primary aliphatic diamines, secondary aliphaticdiamines and mixed diamines (e.g., where one amine site is primary andone amine site is secondary). In other instances, non-aliphatic aminesmay be used in place of an aliphatic amine. If desired, amine reactantswith branching or unsaturation sites can also be used to polymerize theepoxy materials described herein. In some embodiments, the reactant maybe one or more of the Anquamine reactants commercially available fromAir Products, e.g., Anquamine 721, 701, 401, 360, 287, 735 or 419.

In certain embodiments, the dispersions described herein can include oneor more additives or materials to facilitate polymerization, depositionor otherwise alter the properties of the dispersion and any resultingcoating on a substrate. In some embodiments, the additive may be asurfactant that can assist in dispersion of the macromonomers and/orepoxy materials in an aqueous carrier. If desired, the surfactant may beionic or non-ionic. The surfactant can be present in an effective amountto either assist in dispersal of the material in the aqueous carrier orto reduce surface tension of the aqueous dispersion as it is disposed onthe substrate or both. In some instances, the surfactant can also assistin providing a coating that has substantially the same thickness alongthe planar surface of a substrate. Where macromonomers and/or epoxymaterials are used, it may be desirable to use a non-ionic surfactant.In some embodiments, the surfactant may be substituted or derivatizedwith groups other than carbon, hydrogen and oxygen. For example, thesurfactant can include halo groups, (e.g., fluoro, chloro, bromo, oriodo groups), phospho groups, sulfo groups or other groups. In someembodiments, the surfactant can be present in an effective amount toreduce the surface tension of the aqueous dispersion as it is coatedonto a substrate to provide for easier coating and/or a more uniformcoating. Illustrative commercially available surfactants are availablefrom 3M (e.g., Novec fluorosurfactants such as FC-4430, FC-4432,FC-4434), Sigma Aldrich (e.g., Triton™ surfactants, Zonyl® surfactants),Maflon (e.g., PDM112, Hexafor 647, 648, 670, 675 or 678D), AkzoNobel andother companies that provide surfactants.

In other embodiments, the dispersions can include one or more fillers orfiller materials. For example, in some embodiments the filler caninclude one or more of a clay, a montmorillonite, a calcium filler, abentonite, a muscovite, an illite, a cookeite, a kaolonite, a chloriteor other filler materials. The filler may comprise inorganic materials,organic materials or combinations thereof. In some examples, the fillermay provide reinforcement in the cured coating, may provide flameretardancy in the cured coating, may improve the physical properties ofthe cured coating (e.g., increase the coefficient of linear thermalexpansion (CLTE) as compared to the CLTE of a cured coating without thefiller), or may provide other desired features, e.g., may increase theoverall viscosity of the aqueous dispersion to facilitate more uniformcoating on a substrate. Illustrative commercially available fillers,include, but are not limited to, Bentolite®, Cloisite®, Nanofil®,Nanothix®, and Permont® fillers available from Southern Clay Products,Inc.

In certain examples, the dispersions can include one or more biocidalagents. The biocidal agent can be effective to deter or prevent growthof organisms on the coating and/or surface of the substrate. In someembodiments, the biocidal agent can be effective as a fungicide, e.g., amoldicide, to prevent growth of mold or other fungus on the surface ofthe substrate. The biocidal agent can prevent growth of mold and funguson or in the dispersion. In other embodiments, the biocidal agent can beeffective to prevent growth of bacteria, mold, fungus, moss, algae orother organisms on the surface of the substrate. Where present, thebiocidal agent may be present in an effective amount to deter or preventgrowth of bioorganisms.

In some embodiments, the dispersions can include stain-resistanceadditives. In some examples, the stain-resistance additive can act toreduce or prevent materials from being adsorbed into the coating and cangenerally assist in sealing the coating from penetration by materialsother than water and gases. For example, the stain-resistance additivecan provide oil resistance or oil repellency to prevent non-polarspecies from becoming trapped in the coating. The stain-resistanceadditives may also inhibit fading of the coating if exposed to heat,ultraviolet light or other forms of energy. Illustrativestain-resistance additives are commercially available, for example, from3M (e.g., SRC-220, PM-5000, PM-1680, PM-4800) and AkzoNobel (e.g.,Elotex® stain-resistance additives).

In certain embodiments, the dispersions described herein can compriseone or more polyamides or polyamide precursors mixed with macromonomeror epoxy resin. In some instances, the polyamide may be produced fromnaturally occurring polyamide precursors such as those present in castoroil. In other embodiments, the polyamide may be Nylon 6 precursors,e.g., caprolactam, that can be mixed in monomeric form with themacromonomer or the epoxy resin. Where a polyamide precursor is present,it is desirably used in an amount that does not result in phaseseparation in the aqueous dispersion. In some instances, the polyamideprecursors can be used as a reactant in the aqueous dispersion. In otherembodiments, a polyamide, e.g., Nylon 6, can be added to the aqueousdispersion either before or during coating. In yet one furtherembodiment, the coating can be adjacent to a polyamide layer. Thepolyamide layer can include Nylon 6. In one embodiment, the polyamidelayer can range from 0.005 mil to 2 mil, such as from 0.008 mil to 0.1mil, or from 0.01 mil to 0.05 mil.

In certain examples, the aqueous dispersions described herein can beused to provide a cured coating on a building substrate, e.g., kraftpaper of fiberglass insulation, oriented strand board or as a coating ona house wrap or other material used that can be used to seal a buildingenvelope. Referring to FIG. 1A, an article 100 is shown comprising asubstrate 110 with a coating 120 disposed thereon. The exact thicknessof the substrate 110 and the coating 120 can vary, but in most cases thethickness of the substrate 110 will be substantially larger than thethickness of the coating 120. While the thickness of the coating 120 isshown as being substantially the same in the planar direction of thesubstrate 110, such uniformity is not required. In particular, so longas the thickness of the coating 120 is effective to provide the variablewater vapor perm values described herein, the thickness need not beuniform in every area of the substrate 110. In another embodiment and asshown in FIG. 1B, an article 100 comprises a substrate 110 and twocoatings 1202 and 1204 on opposite surfaces of the substrate 110, Thethickness of the coatings 1202 and 1204 can be the same or different.The thicknesses can be chosen to provide the variable water vapor permvalues described herein. In at least one embodiment, the thickness ofcoating 120, 1202, or 1204 can be at least 0.001 cm, such as at least0.01 cm, at least 0.05 cm, at least 0.1 cm, at least 0.12 cm, at least0.14 cm, at least 0.16 cm, at least 0.18 cm, at least 0.20 cm, or atleast 0.22 cm. In another embodiment, the thickness of coating 120,1202, or 1204 can be not greater than 1 cm, such as not greater than 0.9cm, not greater than 0.8 cm, not greater than 0.7 cm, not greater than0.6 cm, not greater than 0.55 cm, not greater than 0.5 cm, not greaterthan 0.45 cm, not greater than 0.4 cm, not greater than 0.35 cm, notgreater than 0.3 cm, not greater than 0.28 cm, not greater than 0.26 cm,or not greater than 0.24 cm. In yet one further embodiment, thethickness of coating 120, 1202, or 1204 can range from 0.001 cm to 1 cm,such as from 0.05 cm to 0.5 cm, or from 0.1 cm to 0.25 cm.

In certain embodiments, the substrate 110 can be any suitable substratecommonly used in the building industry. For example, buildings typicallyhave some form of insulation in the wall, floor and/or ceiling cavities.This insulation is often fiberglass insulation that can include a vaporretarder to prevent moisture from entering the insulated cavities.Common vapor retarders are kraft paper coated with asphalt. Kraft paperitself has a high rate of moisture transmission. When used with anasphalt coating and/or adhesive, the kraft paper can act as a suitablevapor retarder. Reduced moisture in the wall cavity can prevent areduction in the thermal conductivity within the wall cavity, which canfurther assist in reduction of energy costs. In some instances, thesubstrate 110 may be kraft paper that can be applied to a largerbuilding substrate, e.g., fiberglass insulation, using an adhesive orother suitable attachment means. The exact weight of the kraft paper canvary, and illustrative weights include, but are not limited to, about 25pounds to about 75 pounds per ream (3000 ft²), for example about 39pounds. If desired, the kraft paper can be omitted, and the coating 120can be disposed directly on the fiberglass insulation to provide acoating. In some examples where the kraft paper is omitted, it may bedesirable to include a web, scrim, permeable film or some other materialon the fiberglass insulation to receive the aqueous dispersion thatforms the coating. In other embodiments, the substrate may be orientedstrand board that is applied as sheathing on external surfaces of abuilding or between various floors of a building. The oriented strandboard can be coated directly without any intervening film or material toprovide an oriented strand board substrate having variable water vaporperm ratings. In other instances, the coating can be applied directly todrywall or other materials commonly used to finish interior surfaces ofa building structure. For example, gypsum boards can be coated with theaqueous dispersion to provide a gypsum wallboard with variable waterperm ratings. Similarly, wood paneling, wood planks, plywood, fiberboard or other materials used to finish exterior or interior walls orceilings can be coated with the aqueous dispersions described herein toprovide variable water vapor perm ratings. Additional buildingsubstrates that can be coated with the aqueous dispersions will bereadily selected by the person of ordinary skill in the art, given thebenefit of this disclosure.

In yet one further embodiment, the article 100 can further includestriping (not shown) to bond the article to a base material. Thestriping can include an adhesive. In one embodiment, the striping caninclude asphalt. In yet another embodiment, the striping can be watervapor impermeable. The striping can be adjusted to adjust the watervapor perm ratings through the article and the base material. Morestriping reduces the water vapor perm rating, less striping increasesthe water vapor permeance. Accordingly, the striping serves as a vaporretarder across the article and the bonded base material.

In one embodiment, the base material can be any non-woven sheetingmaterial, a gypsum wallboard, a wooden wallboard, a brick wall, or otherbuilding substrates. In one particular embodiment, the base material canbe a porous material. In one particular embodiment, the base materialcan be a foam material.

In certain embodiments, the coating 110 can be disposed on the substrate120 by rolling, spraying, roll coating or other means that can dispose alayer of the aqueous dispersion on the substrate. If desired, additionalaqueous dispersion can be added to a cured coating layer to build up thethickness of the layers of the coating. In some embodiments, it may bedesirable to first coat the substrate with a first aqueous dispersion,e.g., one including a VOMM, and then after curing the first layer coatthe substrate again with a second aqueous dispersion, e.g., oneincluding a waterborne epoxy resin system. In other instances, differentaqueous dispersions can be mixed with each other and coated onto thesubstrate simultaneously. Once cured, the coating on the substratedesirably provides variable water vapor perm ratings, e.g., about 2 permor less at 25% average RH, is less than or equal to 5 perms at 45%average RH, is about 12 perms to about 24 perms at 75% average RH, andis greater than 30 perms at 95% average RH as tested by ASTM D1653; orabout 2.5 perm or less at 25% average RH, is less than or equal to 5perms at 45% average RH, is about 6 perms to about 12 perms at 75%average RH, and is greater than 12 perms at 95% average RH as tested byASTM E96.

In some embodiments, the aqueous dispersion can be co-sprayed onto thesubstrate with a reactant so reaction does not occur prematurely in theaqueous dispersion. For example, where the aqueous dispersion comprisesa VOMM, the dispersion can be co-sprayed with styrene or some otherreactant directly onto the substrate to form the coating. Additionally,one or more surfactants, biocidal agents, filler materials or otheradditives can also be co-sprayed into the surface of the substrate. Insome instances, one component of the coating can be rolled onto thesubstrate and another component, e.g., the reactant, can be sprayed ontothe rolled aqueous dispersion on the substrate. If desired, however, thecomponents can all be mixed in the aqueous dispersion and then disposedon the substrate in a desired manner. In some instances, the aqueousdispersions may have a viscosity that is too low to facilitate easydeposition onto a substrate. In such instances, it may be desirable toinclude a viscosity modifier, e.g., a thixotropic agent, ananti-thixotropic agent, or the like to provide a desirable viscositysuitable for coating or otherwise disposing the aqueous dispersion ontoa desired substrate.

In certain examples, the aqueous dispersions provided herein can be usedeither to provide pre-coated building substrates or to permit on-sitecoating of building substrates. For example, fiberglass insulation battswith kraft paper can be pre-coated with one or more of the componentsfollowed by coating of an additional component on-site to provide thefinal operative coating. In other instances, the coating can be producedat the production site such that an installer need not do anything toprovide the coating. In yet other cases, the installer may spray theaqueous dispersion onto a substrate after it has been installed toprovide the coating on the installed substrate. In some instances, thesubstrate may be a cellulosic substrate, e.g., one based on wood orprepared, at least in part, using wood, wood fibers, wood products orother plant materials that include cellulose.

In certain examples, the components of the coatings described herein maybe packaged in the form of a kit. In one embodiment, the kit can includea coating dispersion and an applicator to provide the coating dispersiononto a substrate. The applicator can be a brush, a spray nozzle, or aroller. In another embodiment, the kit can include a precursor to thecoating dispersion. For example, materials suitable for providing anaqueous dispersion, e.g., a macromonomer or a waterborne epoxy resin,can be packaged separate from a reactant and any other additives, e.g.,fillers, surfactants or the like. The components can be mixed by a user,and the mixed components may then be coated onto a substrate. In someembodiments, the kit may be packaged as a 2-part kit where the variouscomponents of the coating are mixed in-line prior to spraying ordepositing on the substrate.

For example, one canister or reservoir can include a polymerizablecomponent and the other canister or reservoir can include a reactantand/or other additives. During application, the system or device, e.g.,a sprayer or similar device, can mix the two different componentsin-line prior to spraying. In some examples, an aqueous carrier can beadded to the components immediately prior to mixing. In some instances,the aqueous carrier can be mixed with the components using an impeller,gas or other means to facilitate dispersion of the components in theaqueous carrier.

One aspect to the present coatings is the low content of VOCs duringpreparation and/or curing of the coatings. VOC content can be determinedby ASTM D3960 and be quantified mass of VOC per mass unit of coatingsolids. In one embodiment, as tested by ASTM D3960, the VOC content ofthe herein described coatings is less than 3 wt %, such as less than 1wt %, less than 0.5 wt %, less than 100 ppm, less than 50 ppm, less than40 ppm, less than 30 ppm, less than 20 ppm, less than 10 ppm, less than5 ppm, less than 1 ppm, less than 0.5 ppm, or less than 0.1 ppm.

Certain specific examples are described below to facilitate a betterunderstanding of the technology described herein.

EXAMPLE 1

All coating systems were applied on kraft paper with a wirewound bar andallowed to dry at ambient for one week before evaluation. The coatedpaper was placed in perm cups with flanged edges and the cups wereplaced in an environmental chamber that provided mean RH levels of 25%,45%, 75% and 95% to evaluate the water permeability following the ASTMD1653 and/or E96 protocol. The coated side of the paper was kept facingthe high humidity side in all evaluations. Each cup containing thecoated paper along with water/desiccant was weighed before being placedin the environmental chamber and weighed every day thereafter for 10days. A 2 mil nylon 6 film was employed as an internal control in everytest. Each system was analyzed in triplicate and the average wasreported. The experimental conditions were as described in Table 1. Thetarget perm values for the coatings are listed in Table 2.

TABLE 1 Experimental Setup Environmental Chamber RH Cup (Air Temperaturein Chamber: 70-73° F.) Containing 50% 90% Desiccant 25% mean RH for testsample 45% mean RH for test sample Water 75% mean RH for test sample 95%mean RH for test sample

TABLE 2 Target Perm Values ASTM ASTM Average Relative D1653 E96 Humidity(RH) Perms Perms 25% ≦2.0 ≦1.0 50% ≦5.0 ≦2.5 75% 12-24 6-12 95% >25 >17 

A number of aqueous dispersions were evaluated including:

-   a) Michem® Emulsion D310 (MED310), a multi-purpose aqueous    dispersion of a high melt polyamide supplied by Michelman, Inc. at    22-24% solids by weight, <100 cPs (spindle #3, 60 rpm), pH 9.7-10.7;-   b) Neocar® 820 (an ultra-small particle size, hydrophobic modified    acrylic latex, supplied by Arkema, Inc.);-   c) ENCOR® 443 is a styrene-acrylic latex (41% solids by weight,    viscosity 600 cPs, density 8.7 lb/gal, and pH 7.0);-   d) A SoyAA-1:styrene (46:54 by weight) latex (50% solids by weight)    referred to as EK 3-32R2 in the Table 3 below;-   e) Ancarez® AR555 (a waterborne solid epoxy resin dispersion    delivered at 55% solids in water, epoxy equivalent weight 550,    supplied by Air Products and Chemicals, Inc.). The epoxy resin is    based on diglycidyl ether of bisphenol-A; and-   f) Anquamine® 401 (a modified aliphatic amine supplied at 70% solids    in water, theoretical amine hydrogen equivalent weight 200, employed    here as a reactant for Ancarez AR555, supplied by Air Products and    Chemicals, Inc.).

Additives employed in this Example include:

-   a) Oxylink® 3101 is an aqueous dispersion containing nano zinc oxide    (44% solids in water, pH 7-9, VOC <0.2%, viscosity <10 mPa·sec,    density 1.5-1.6 g/mL, supplied by Buhler, Inc.)-   b) Nanofil aqueous dispersion (Nanofil 116 is a natural    montmorillonite clay, supplied by Southern Clay Products, Inc., the    aqueous dispersion was prepared in our lab)-   c) SRC-220 (an aqueous fluorinated polyurethane stain-resistance    additive, supplied by 3M)-   d) FC-4434 (a nonionic fluorinated surfactant, supplied by 3M)-   e) Nanobyk® 3810 (a cerium oxide nanoparticle dispersion in water,    supplied by BYK Additives)-   f) Cobalt Hydrocure® (a drier containing 6% cobalt metal, supplied    by OM Group, Inc.)

To obtain a baseline value for the substrate and the control, the firstevaluation was conducted with kraft paper, nylon, and kraft paper+nylonalong with kraft paper coated individually with the polyamide emulsionand SoyAA-1/styrene latex. The perm values obtained during theevaluation are listed in Table 3.

TABLE 3 ASTM D1653 Perm Results-I Average RH Desired Perms Substratewith no Coating Perms 25% RH ≦2.0 Kraft paper 28.46 Nylon 1.58 Kraftpaper + Nylon 3.18 45% RH ≦5.0 Kraft paper — Nylon 4.19 Kraft paper +Nylon 10.26 75% RH 12-24 Kraft paper 157.51 Nylon 14.79 Kraft paper +Nylon 17.51 95% RH >25 Kraft paper 363.32 Nylon 68.63 Kraft paper +Nylon 66.87 Average RH Desired Perms Coating on Kraft Paper Perms 25% RH≦2.0 MED 310 21.00 EK 3-32R2 17.54 45% RH ≦5.0 MED 310 29.77 EK 3-32R210.10 75% RH 12-24 MED 310 157.69 EK 3-32R2 64.03 95% RH >25 MED 310275.00 EK 3-32R2 54.42

EXAMPLE 2

Three systems were evaluated, i.e., a) SoyAA-1/styrene (referred to asEK 3-32R2 in Tables 4 and 5 below) with 1% Oxylink, b) SoyAA-1/styrene(repeat), and c) nylon (repeat) at 45% and 90% RH levels. The repeatswere necessary to determine the repeatability of the systems. Theresults are provided in Table 4. The ASTM D1653 protocol was used forthe testing.

TABLE 4 ASTM D1653 Perm Results-II Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 45% RH ≦5.0 EK 3-32R2 8.7716.38 EK 3-32R2 + 1% Oxylink 8.90 14.69 95% RH >25 EK 3-32R2 120.1414.70 EK 3-32R2 + 1% Oxylink 77.56 17.55

At 45% RH level, a good reproducibility was noted between the second andthird iterations for nylon and SoyAA-1/styrene. At the 95% RH level,only the nylon sample showed good reproducibility. Of the three samplestested with SoyAA-1/styrene, one sample gave extremely high water lossreadings, indicating that the sample might have had some tear thatallowed water vapor to move freely. Overall, incorporating 1% Oxylink tothe SoyAA-1/styrene latex seemed to have a positive effect on thepermeability values of the coated kraft paper, i.e., it moved the permvalues closer to the target perm values (Table 5).

TABLE 5 ASTM D1653 Perm Results-III Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 EK 3-32R2 7.9215.47 EK 3-32R2 + 1% Oxylink 7.36 16.62 75% RH 12-24 EK 3-32R2 89.7412.98 EK 3-32R2 + 1% Oxylink 66.60 14.45

At 25% RH level, the system with 1% Oxylink performed better than thesystem without Oxylink.

EXAMPLE 3

Blends of MED 310 with SoyAA-1/styrene (46:54 by weight and referred toas EK 3-32R2 in Table 6 below) in the ratios of a) 65:35, b) 35:65, andc) 50:50 (all on solids by weight), and a blend of MED 310 with ENCOR443 at 50:50 by weight on solids were applied on kraft paper andevaluated at 25% and 75% RH levels. The results are provided in Table 6.The ASTM D1653 protocol was used for the testing.

TABLE 6 ASTM D1653 Perm Results-IV Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 MED 310:EK 3-32R235:65 38.36 10.68 MED 310:EK 3-32R2 50:50 37.96 9.04 MED 310:Encor 43350:50 42.07 9.43 75% RH 12-24 MED 310:EK 3-32R2 35:65 99.18 10.41 MED310:EK 3-32R2 50:50 142.29 10.04 MED 310:Encor 433 50:50 159.11 8.98

The MED 310 blends exhibited phase separation upon application to thekraft paper that was manifest as areas with uneven gloss and appearance.The phase separation is believed to compromise the water vaporpermeability of the coated system as noted from the high permeabilityvalues. Consequently, these systems were not evaluated at 45% and 95% RHlevels.

EXAMPLE 4

The following systems were applied on kraft paper and evaluated at 25%and 75% RH levels:

-   1) Ancarez AR555, a waterborne solid epoxy resin dispersion supplied    at 55% solids in water,-   2) Encor 443,-   3) Encor 443+3% Oxylink 3101,-   4) SoyAA-1/styrene (46:54 by weight and referred to as EK 3-32R2 in    Table 7 below)+1% Oxylink 3101,-   5) SoyAA-1/styrene (46:54 by weight)+3% Oxylink 3101,-   6) SoyAA-1/styrene (46:54 by weight)+1% Nanofil aqueous dispersion,-   7) SoyAA-1/styrene (46:54 by weight)+3% Nanofil,-   8) SoyAA-1/styrene (46:54 by weight) with 0.5% SRC-220,-   9) SoyAA-1/styrene (46:54 by weight)+0.1% FC-4434, and-   10) SoyAA-1/styrene (46:54 by weight)+0.4% Nanobyk 3810

The samples described in Table 7 were coated at 5 mils wet filmthickness. The ASTM D1653 protocol was used for the testing. In thisevaluation, the SoyAA-1/styrene+1% Oxylink 3101 was applied at 3 milswet film thickness while the SoyAA-1/styrene+3% Oxylink 3101 was appliedat 1 mil wet film thickness. The perm results together with the coatingweights for this evaluation are listed in Table 7.

TABLE 7 ASTM D1653 Perm Results-V Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 Ancarez AR 5555.03 5.69 Encor 443 42.40 4.84 Encor 443 with 3% Oxylink 3101 40.70 5.02EK 3-32R2 with 1% Oxylink 3101 43.10 4.06 EK 3-32R2 with 3% Oxylink 310137.33 2.24 EK 3-32R2 with 1% Nanofil 6.20 8.37 EK 3-32R2 with 3% Nanofil6.78 7.73 EK 3-32R2 with 0.5% SRC-220 10.14 8.02 EK 3-32R2 with 0.1% FC4434 7.32 8.70 EK 3-32R2 with 0.4% Nanobyk 9.15 7.81 3810 75% RH 12-24Ancarez AR 555 32.72 5.88 Encor 443 123.97 3.72 Encor 443 with 3%Oxylink 3101 121.37 4.77 EK 3-32R2 with 1% Oxylink 3101 119.66 3.41 EK3-32R2 with 3% Oxylink 3101 121.64 2.43 EK 3-32R2 with 1% Nanofil 48.127.68 EK 3-32R2 with 3% Nanofil 26.83 9.93 EK 3-32R2 with 0.5% SRC-22023.00 8.83 EK 3-32R2 with 0.1% FC 4434 38.47 9.28 EK 3-32R2 with 0.4%Nanobyk 63.57 8.61 3810

To meet the target perm ratings at 25% and 75% RH, the coating weightsfor the systems need to be increased.

EXAMPLE 5

Separate systems including Ancarez 550 and Neocar 820 were tested. Thesystems that were applied on kraft paper were comprised of:

-   1) Ancarez AR555 with 1% Nanofil-   2) Ancarez AR555 with 3% Nanofil-   3) Ancarez AR555 with SRC-220 and FC-4434-   4) Ancarez AR555 with SRC-220-   5) Ancarez AR555 with FC-4434-   6) Neocar 820 with 1% Nanofil-   7) Neocar 820 with 3% Nanofil-   8) Neocar 820 with SRC-220 and FC-4434-   9) Neocar 820 with SRC-220-   10) Neocar 820 with FC-4434

The perm results of this evaluation are provided in Table 8. The ASTMD1653 protocol was used for the testing.

TABLE 8 ASTM D1653 Perm Results-VI Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 Ancarez AR 555 +1% Nanofil 4.11 17.16 Ancarez AR 555 + 3% Nanofil 6.51 14.24 Ancarez AR555 + SRC-220 + 5.96 14.86 FC-4434 Ancarez AR 555 + SRC-220 7.61 12.98Ancarez AR 555 + FC-4434 5.59 14.35 Neocar 820 + 1% Nanofil 8.54 13.01Neocar 820 + 3% Nanofil 8.65 13.00 Neocar 820 + SRC-220 + FC-4434 6.8414.10 Neocar 820 + SRC-220 6.08 14.36 Neocar 820 + FC-4434 10.00 11.3075% RH 12-24 Ancarez AR 555 + 1% Nanofil 40.52 12.24 Ancarez AR 555 + 3%Nanofil 39.01 13.58 Ancarez AR 555 + SRC-220 + 35.25 13.17 FC-4434Ancarez AR 555 + SRC-220 39.72 12.01 Ancarez AR 555 + FC-4434 36.9212.51 Neocar 820 + 1% Nanofil 51.61 11.62 Neocar 820 + 3% Nanofil 23.1913.08 Neocar 820 + SRC-220 + FC-4434 17.49 12.78 Neocar 820 + SRC-22016.41 11.76 Neocar 820 + FC-4434 43.56 11.82

EXAMPLE 6

The most promising systems from Tables 5 and 6 were selected forevaluation at 45% and 95% RH.

1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-32R2 in Table9)+FC-4434

2) Ancarez AR555

3) Ancarez AR555+1% Nanofil

4) Ancarez AR555+SRC-220+FC-4434

5) Ancarez AR555+FC-4434

6) Neocar 820+3% Nanofil

7) Neocar 820+SRC-220+FC-4434

8) Neocar 820+SRC-220

The perm results of this evaluation are listed in Table 9. The ASTMD1653 protocol was used for the testing.

TABLE 9 ASTM D1653 Perm Perm Results-VII Coating Average Desired WeightRH Perms Coating on Kraft Paper Perms (g/ft²) 45% RH ≦5.0 EK 3-32R2 +0.1% FC-4434 11.13 8.11 Ancarez AR 555 10.31 5.19 Ancarez AR 555 + 1%Nanofil 6.89 7.29 Ancarez AR 555 + SRC-220 + 7.34 9.74 FC-4434 AncarezAR 555 + FC-4434 6.91 7.87 Neocar 820 + 3% Nanofil 7.09 8.38 Neocar820 + SRC-220 + FC-4434 6.13 7.48 Neocar 820 + SRC-220 11.92 3.99 95%RH >25 EK 3-32R2 + 0.1% FC-4434 81.79 10.06 Ancarez AR 555 114.38 6.59Ancarez AR 555 + 1% Nanofil 153.54 6.92 Ancarez AR 555 + SRC-220 +117.54 10.42 FC-4434 Ancarez AR 555 + FC-4434 129.31 9.14 Neocar 820 +3% Nanofil 100.07 9.84 Neocar 820 + SRC-220 + FC-4434 41.22 8.27 Neocar820 + SRC-220 58.13 6.46

At 45% RH, none of the above systems met the target perm rating but allmet the target at 95% RH.

EXAMPLE 7

Several additional systems were evaluated at 45% and 95% RH:

-   -   1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-32R2 in        Table 10)+1% Nanofil    -   2) SoyAA-1/styrene (46:54 by weight)+3% Nanofil    -   3) Neocar 820+1% Nanofil    -   4) Ancarez AR555+SRC-220    -   5) Ancarez AR555+3% Nanofil    -   6) Ancarez AR555 crosslinked with Anquamine 401 (epoxy:amine        ratio 2:1)

The perm results of this evaluation are listed in Table 10. The ASTMD1653 protocol was used for the testing.

TABLE 10 ASTM D1653 Perm Results-VIII Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 45% RH ≦5.0 EK 3-32R2 + 1%Nanofil 18.77 6.02 EK 3-32R2 + 3% Nanofil 18.36 9.09 Neocar 820 + 1%Nanofil 11.89 6.70 Ancarez AR 555 + SRC-220 10.93 7.90 Ancarez AR 555 +3% Nanofil 6.91 10.26 Ancarez AR 555 crosslinked with 3.55 12.79Anquamine 401 95% RH >25 EK 3-32R2 + 1% Nanofil 88.72 7.69 EK 3-32R2 +3% Nanofil 123.03 8.39 Neocar 820 + 1% Nanofil 22.77 9.72 Ancarez AR555 + SRC-220 93.47 9.67 Ancarez AR 555 + 3% Nanofil 145.89 9.12 AncarezAR 555 crosslinked with 26.00 13.03 Anquamine 401

Only Ancarez AR 555 crosslinked with Anquamine 401 system met thedesired perms as Table 10 showed.

EXAMPLE 8

The following samples were evaluated at all four RH levels.

1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-85 in Table 11)(5 mils)

2) SoyAA-1/styrene (46:54 by weight) with 1% Nanofil+FC-4434 (3 mils)

3) SoyAA-1/styrene (46:54 by weight) with 1% Nanofil+FC-4434 (5 mils)

4) SoyAA-1/styrene (46:54 by weight)+FC-4434 (5 mils)

5) Neocar 820+FC-4434

The perm results of this evaluation are listed in Table 11. The ASTMD1653 protocol was used for the testing.

TABLE 11 ASTM D1653 Perm Results-IX Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 EK 3-85 7.89 7.27EK 3-85 + Nanofil + FC-4434 9.47 4.45 (3 mils) EK 3-85 + Nanofil +FC-4434 6.88 7.63 (5 mils) EK 3-85 + FC-4434 10.02 6.55 Neocar 820 +FC-4434 5.22 4.89 45% RH <5.0 EK 3-85 7.53 7.94 EK 3-85 + Nanofil +FC-4434 8.93 4.43 (3 mils) EK 3-85 + Nanofil + FC-4434 7.89 7.88 (5mils) EK 3-85 + FC-4434 7.14 7.93 Neocar 820 + FC-4434 6.94 8.25 75% RH12-24 EK 3-85 24.73 7.76 EK 3-85 + Nanofil + FC-4434 53.11 3.99 (3 mils)EK 3-85 + Nanofil + FC-4434 23.45 7.57 (5 mils) EK 3-85 + FC-4434 33.107.02 Neocar 820 + FC-4434 15.12 8.35 95% RH >25 EK 3-85 64.20 8.20 EK3-85 + Nanofil + FC-4434 119.17 5.26 (3 mils) EK 3-85 + Nanofil +FC-4434 54.69 9.91 (5 mils) EK 3-85 + FC-4434 113.07 6.37 Neocar 820 +FC-4434 107.53 6.97

None of the tested systems met the target perm ratings at 25%, 45% and75% RH due to low coating weights on the kraft paper substrate. However,all systems met the target perm ratings at 95% RH.

EXAMPLE 9

In the next round of testing, the following systems were evaluated atall four RH levels:

-   -   1) SoyAA-1/styrene (46:54 and listed as EK 4-23 in Table 12)    -   2) SoyAA-1/styrene (46:54 and listed as EK 4-25 in Table 12)    -   3) AR555+1% Nanofil+0.1% FC-4434    -   4) AR555+1% Nanofil+0.2% FC-4434    -   5) AR555+1% Nanofil+0.5% SRC-220    -   6) AR555+1% Nanofil+0.2% FC-4434+0.5% SRC-220    -   7) AR555+1% Nanofil+0.1% FC-4434+1% SRC-220    -   8) SoyAA-1/styrene (46:54 and listed as EK 3-85 in Table 12)+1%        Nanofil+0.1% FC-4434    -   9) SoyAA-1/styrene (46:54)+1% Nanofil+0.2% FC-4434    -   10) SoyAA-1/styrene (46:54)+1% Nanofil+0.1% FC-4434+0.5% SRC-220    -   11) SoyAA-1/styrene (46:54)+1% Nanofil+0.2% FC-4434+0.5% SRC-220    -   12) SoyAA-1/styrene (46:54)+1% Nanofil+0.1% FC-4434+1% SRC-220    -   13) SoyAA-1/styrene (46:54)+2% Nanofil+0.1% FC-4434

The perm results of this evaluation are listed in Table 12. The ASTMD1653 protocol was used for the testing.

TABLE 12 ASTM D1653 Perm Results-X Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 EK 4-23 8.34 7.23EK 4-25 9.39 6.91 AR 555 + 1% Nanofil + 0.1% 3.81 12.53 FC4434 AR 555 +1% Nanofil + 0.2% 3.76 12.83 FC4434 AR 555 + 1% Nanofil + 0.5% SRC 4.5311.34 220 AR 555 + 1% Nanofil + 0.2% FC 4.41 11.93 4434 + 0.5% SRC 220AR 555 + 1% Nanofil + 0.1% FC 3.81 12.43 4434 + 1% SRC 220 EK 3-85 + 1%Nanofil + 0.1% FC 8.67 7.12 4434 EK 3-85 + 1% Nanofil + 0.2% FC 8.297.15 4434 EK 3-85 + 1% Nanofil + 0.1% FC 6.27 8.42 4434 + 0.5% SRC 220EK 3-85 + 1% Nanofil + 0.2% FC 7.66 7.53 4434 + 0.5% SRC 220 EK 3-85 +1% Nanofil + 0.1% FC 6.59 8.00 4434 + 1% SRC 220 EK 3-85 + 2% Nanofil +0.1% FC 6.07 9.19 4434 45% RH <5.0 EK 4-23 5.48 6.71 EK 4-25 5.60 6.90AR 555 + 1% Nanofil + 0.1% 4.40 12.72 FC4434 AR 555 + 1% Nanofil + 0.2%5.01 11.83 FC4434 AR 555 + 1% Nanofil + 0.5% SRC 4.43 10.26 220 AR 555 +1% Nanofil + 0.2% FC 5.06 11.95 4434 + 0.5% SRC 220 AR 555 + 1%Nanofil + 0.1% FC 4.61 11.95 4434 + 1% SRC 220 EK 3-85 + 1% Nanofil +0.1% FC 5.69 9.47 4434 EK 3-85 + 1% Nanofil + 0.2% FC 5.45 8.38 4434 EK3-85 + 1% Nanofil + 0.1% FC 5.49 9.91 4434 + 0.5% SRC 220 EK 3-85 + 1%Nanofil + 0.2% FC 5.45 10.38 4434 + 0.5% SRC 220 EK 3-85 + 1% Nanofil +0.1% FC 5.60 9.70 4434 + 1% SRC 220 EK 3-85 + 2% Nanofil + 0.1% FC 5.608.72 4434 75% RH 12-24 EK 4-23 30.49 7.03 EK 4-25 36.56 7.34 AR 555 + 1%Nanofil + 0.1% FC 44.70 13.30 4434 AR 555 + 1% Nanofil + 0.2% FC 42.7913.28 4434 AR 555 + 1% Nanofil + 0.5% SRC 45.98 12.37 220 AR 555 + 1%Nanofil + 0.2% FC 43.40 11.52 4434 + 0.5% SRC 220 AR 555 + 1% Nanofil +0.1% FC 43.20 12.07 4434 + 1% SRC 220 EK 3-85 + 1% Nanofil + 0.1% FC31.36 8.50 4434 EK 3-85 + 1% Nanofil + 0.2% FC 40.85 6.96 4434 EK 3-85 +1% Nanofil + 0.1% FC 26.28 8.81 4434 + 0.5% SRC 220 EK 3-85 + 1%Nanofil + 0.2% FC 34.07 7.91 4434 + 0.5% SRC 220 EK 3-85 + 1% Nanofil +0.1% FC 36.38 8.09 4434 + 1% SRC 220 EK 3-85 + 2% Nanofil + 0.1% FC28.49 12.41 4434 95% RH >25 EK 4-23 43.60 7.57 EK 4-25 110.92 6.18 AR555 + 1% Nanofil + 0.1% FC 152.52 12.75 4434 AR 555 + 1% Nanofil + 0.2%FC 131.98 12.25 4434 AR 555 + 1% Nanofil + 0.5% SRC 144.36 11.35 220 AR555 + 1% Nanofil + 0.2% FC 137.05 11.44 4434 + 0.5% SRC 220 AR 555 + 1%Nanofil + 0.1% FC 136.66 12.42 4434 + 1% SRC 220 EK 3-85 + 1% Nanofil +0.1% FC 85.95 7.61 4434 EK 3-85 + 1% Nanofil + 0.2% FC 55.73 8.11 4434EK 3-85 + 1% Nanofil + 0.1% FC 47.94 8.13 4434 + 0.5% SRC 220 EK 3-85 +1% Nanofil + 0.2% FC 44.67 9.66 4434 + 0.5% SRC 220 EK 3-85 + 1%Nanofil + 0.1% FC 60.48 8.13 4434 + 1% SRC 220 EK 3-85 + 2% Nanofil +0.1% FC 74.16 9.68 4434

None of the systems met the target perm rating at 25% RH, whereas sometested systems met the perm ratings at 45% RH, 75% RH and 95% RH.

EXAMPLE 10

The following samples were evaluated at all four RH levels. The resultsare listed in Table 13. The ASTM D1653 protocol was used for thetesting.

-   -   1) SoyAA-1/styrene (46:54 by weight and listed as EK 3-85 in        Table 13) (2 month sample)    -   2) SoyAA-1/styrene (46:54 by weight and listed as EK 3-32R6 in        Table 13)+0.1% Cobalt Hydrocure II metal on resin solids    -   3) SoyAA-1/styrene (46:54 by weight)+3% Additol as supplied on        resin solids    -   4) SoyAA-1/styrene (46:54 by weight)+1% Oxycoat as supplied on        resin solids    -   5) SoyAA-1/styrene (46:54 by weight)+2% Nanofil+0.2% FC-4434    -   6) SoyAA-1/styrene (46:54 by weight)+2% Nanofil+0.1%        FC-4434+0.5% SRC-220    -   7) SoyAA-1/styrene (46:54 by weight)+2% Nanofil+0.2% FC-4434+1%        SRC-220    -   8) AR555+2% Nanofil+0.1% FC-4434    -   9) AR555+2% Nanofil+0.2% FC-4434    -   10) AR555+2% Nanofil+0.1% FC-4434+0.5% SRC-220    -   11) AR555+2% Nanofil+0.2% FC-4434+1% SRC-220

TABLE 13 ASTM D1653 Perm Results-XI Coating Average Desired Weight RHPerms Coating on Kraft Paper Perms (g/ft²) 25% RH ≦2.0 EK 3-85 (2 monthsample) 7.64 7.88 EK 3-32R6 + 0.1% Cobalt 10.29 7.40 Hydrocure II metalon resin solids EK 3-32R6 + 3% Additol as 11.89 3.98 supplied on resinsolids EK 3-32R6 + 1% Oxycoat as 10.50 4.28 supplied on resin solids EK3-85 + 2% Nanofil + 0.2% 6.61 4.90 FC4434 EK 3-85 + 2% Nanofil + 0.1%7.94 9.06 FC4434 + 0.5% SRC 220 EK 3-85 + 2% Nanofil + 0.2% 8.37 8.24FC4434 + 1% SRC 220 AR555 + 2% Nanofil + 0.1% 10.18 7.84 FC4434 AR555 +2% Nanofil + 0.2% 5.05 8.71 FC4434 AR555 + 2% Nanofil + 0.1% 6.75 9.89FC4434 + 0.5% SRC220 AR555 + 2% Nanofil + 0.2% 8.15 10.01 FC4434 + 1%SRC220 45% RH <5.0 EK 3-85 (2 month sample) — — EK 3-32R6 + 0.1% Cobalt6.13 9.58 Hydrocure II metal on resin solids EK 3-32R6 + 3% Additol as6.72 5.92 supplied on resin solids EK 3-32R6 + 1% Oxycoat as 7.45 5.75supplied on resin solids EK 3-85 + 2% Nanofil + 0.2% 7.85 7.92 FC4434 EK3-85 + 2% Nanofil + 0.1% 6.99 7.33 FC4434 + 0.5% SRC 220 EK 3-85 + 2%Nanofil + 0.2% 7.52 6.96 FC4434 + 1% SRC 220 AR555 + 2% Nanofil + 0.1%6.84 9.93 FC4434 AR555 + 2% Nanofil + 0.2% 9.58 7.86 FC4434 AR555 + 2%Nanofil + 0.1% FC4434 + 0.5% SRC220 5.38 9.23 AR555 + 2% Nanofil + 0.2%5.75 9.48 FC4434 + 1% SRC220 75% RH 12-24 EK 3-85 (2 month sample) 20.786.54 EK 3-32R6 + 0.1% Cobalt 26.07 7.53 Hydrocure II metal on resinsolids EK 3-32R6 + 3% Additol as 28.81 4.79 supplied on resin solids EK3-32R6 + 1% Oxycoat as 40.59 4.69 supplied on resin solids EK 3-85 + 2%Nanofil + 0.2% 22.26 10.57 FC4434 EK 3-85 + 2% Nanofil + 0.1% 21.4110.26 FC4434 + 0.5% SRC 220 EK 3-85 + 2% Nanofil + 0.2% 20.36 9.52FC4434 + 1% SRC 220 AR555 + 2% Nanofil + 0.1% 39.81 10.52 FC4434 AR555 +2% Nanofil + 0.2% 39.93 11.95 FC4434 AR555 + 2% Nanofil + 0.1% 44.9310.73 FC4434 + 0.5% SRC220 AR555 + 2% Nanofil + 0.2% 38.06 11.25FC4434 + 1% SRC220 95% RH >25 EK 3-85 (2 month sample) — — EK 3-32R6 +0.1% Cobalt 163.82 7.51 Hydrocure II metal on resin solids EK 3-32R6 +3% Additol as 151.02 6.13 supplied on resin solids EK 3-32R6 + 1%Oxycoat as 119.80 6.11 supplied on resin solids EK 3-85 + 2% Nanofil +0.2% 120.13 7.13 FC4434 EK 3-85 + 2% Nanofil + 0.1% 110.79 8.73 FC4434 +0.5% SRC 220 EK 3-85 + 2% Nanofil + 0.2% 135.97 8.86 FC4434 + 1% SRC 220AR555 + 2% Nanofil + 0.1% 229.11 9.68 FC4434 AR555 + 2% Nanofil + 0.2%190.38 10.51 FC4434 AR555 + 2% Nanofil + 0.1% 192.27 9.89 FC4434 + 0.5%SRC220 AR555 + 2% Nanofil + 0.2% 238.66 11.16 FC4434 + 1% SRC220

EXAMPLE 10

The following systems were selected for testing along with a Nylon 6control

TABLE 14b Ancarez AR555 + 1% Nanofil + 0.1% FC-4434 Raw Materials Grams% Solids Ancarez AR555 97.05 55.0 Nanofil base 2.85 19.3 FC-4434 0.10Total 100.00

TABLE 14a SoyAA-1/styrene + 2% Nanofil + 0.1% FC-4434 Raw MaterialsGrams % Solids SoyAA- 94.99 50.0 1/styrene (46:54 by weight) Nanofilbase 4.92 19.3 FC-4434 0.09 Total 100.00

TABLE 14c Ancarez AR555 + 1% Nanofil + 0.1% FC-4434 + 1% SRC-220 RawMaterials Grams % Solids Ancarez AR555 96.09 55.0 Nanofil Base 2.82 19.3FC-4434 0.10 SRC-220 0.99 Total 100.00

The Nanofil base mentioned in the above tables was prepared under highshear in a Ross mixer by slowly adding Nanofil 116 to water as per theproportion described in Table 15.

TABLE 15 Nanofil Base Raw Material Grams % Solids Nanofil 116 19.30 100Water 80.70 — Total 100.00

An additional system including a reduced cross-linker was also tested asshown in Table 16.

TABLE 16 Ancarez AR555 with Reduced Crosslinker Raw Materials Grams %Solids Ancarez AR555 98.35 55 Anquamine 401 1.65 70 Total 100.00

Each of the systems represented by the four formulations in Tables14a-14c and 16 were applied on three (3) sheets of 6″×12″ kraft paper.The coating weights expressed in g/ft2 and determined over 1 inchsquares of the coated sheets are listed in Table 17.

TABLE 17 Coating Weights Weight System (g/ft²) AR555 + 1% Nanofil + 0.1%FC-4434 1.703 SoyAA-1/styrene (EK 3-85) + 2% Nanofil + 0.1% 2.810FC-4434 AR555 + 1% Nanofil + 0.1% FC-4434 + 1% SRC-220 1.803 AR555 withreduced crosslinker (Table 16) 1.867

Some of the results of the testing are shown in FIG. 2. The ASTM D1653protocol was used for the testing. As can be seen from the graph, thetested coatings provided perm ratings similar to those provided by theNylon 6 control. For reference purposes, the SoyAA-1/styrene sample islabeled as EK 3-85 in the graph. At 25% RH, the Ancarez AR555+1%Nanofil+0.1% FC4434 provided a perm rating of 3.81 perms, the other twocoatings provided a perm rating of about 6.1 perms while the Nylon 6film control sample had 1.58 perms. The SoyAA-1/styrene system provideda perm rating of about 5.6 perms at 45% average RH while the Nylon 6film had 9.78 perms. At 75% RH, only the Neocar 820+SRC-220+FC4434system provided similar perm to the Nylon 6 film sample. All samplesshowed greater than 17 perms at 95% RH.

EXAMPLE 11

The following system was selected for testing along with a Nylon 6control following ASTM E 96 standard test method:

TABLE 18 Ancarez AR555 + Anquamine 401 Raw Materials Grams % SolidsAncarez AR555 66.67 55 Anquamine 401 33.33 70 Total 100.00

The ASTM E96 water vapor permeance test results for the Nylon 6 filmcontrol sample and the Ancarez AR555+Anquamine 401 coating system onkraft paper sample are shown in Table 19 and plotted in FIG. 3.

TABLE 19 ASTM E96 Test Results Water Vapor Permeance Test Results PerASTM E96 for Ancarez AR555 + Anquamine 401 Item Dry Cup Wet Cup Dry CupWet Cup Chamber RH (%) 50 90 Mean RH (%) 25 75 45 95 Target permeancevalues <1 6-12 <2.5 >17 Permeance (perms) 0.79 6.86 1.68 17.28 WaterVapor Permeance Test Results Per ASTM E96 for 2 mil Nylon 6 Film ItemDry Cup Wet Cup Dry Cup Wet Cup Chamber RH (%) 50 90 Mean RH (%) 25 7545 95 Permeance (perms) 0.62 9.71 1.81 34.81

The results in Table 19 and plotted in FIG. 3 show that the testedcoating on kraft provided perm ratings similar to those provided by theNylon 6 control for three of all four average RH values except the 95%RH. At 25% RH, the Ancarez AR555+Anquamine 401 coating system provided aperm rating of 0.79 perms while the Nylon 6 film had 0.62 perms. TheAncarez AR555+Anquamine 401 coating system on kraft provided a permrating of 1.68 perms while the Nylon 6 film control sample had 1.81perms at 45% RH. Even though the Ancarez AR555+Anquamine 401 coatingsystem on kraft provided a 6.86 perms rating at 75% RH, which is lowerthan the Nylon 6 film (9.71 perms), it still meets the target of 6-12perms. At 95% RH the Ancarez AR555+Anquamine 401 coating system on kraftprovided a 17.28 perms rating, which is slightly greater than the targetof 17 perms.

EXAMPLE 12

Anquamine 401 is diluted with water by adding 4 weight parts water to 1weight part of Anquamine 401 (AQ401). The dilution is mixed withmoderate shear at ambient conditions for 15 minutes to avoid formationof foam. Then, Ancarez AR555 is added to the diluted Anquamine 401solution in a ratio of 3 weight parts Ancarez AR555 to 1.25 weight partsof diluted Anquamine 401 and stirred for 15 minutes at moderate shearand ambient condition. The resulting blend was applied onto kraft papersheets. Table 20 lists the weight ratio of the ingredient. Tables 21Aand 21B show the results of the ASTM E96 tests. The results are alsosummarized in FIG. 4.

TABLE 20 Solids Weight Wt % % Solids Ancarez AR555 1.80 70.59 55 39.82Anquamine 401 0.60 23.53 70 16.47 Water 0.15 5.88 0.00 2.55 100.00 55.29Desired coverage (g/m²)-Min 55 Desired coverage (g/m²)-Max 60 Wetcoating weight in lb required/m²- 0.2406 Min Wet coating weight in lbrequired/m²- 0.2624 Max

TABLE 21 A Test A: Water Vapor Permeance for Coated Kraft Sample WaterVapor Permeance, perms Replicate 25% Mean RH 45% Mean RH Sample 1 1.333.86 Formulation: AR555 + 2 1.29 3.90 AQ401 3 1.07 3.29 Mean 1.23 3.68SD 0.14 0.34 Water Vapor Permeance, perms Replicate 75% Mean RH 95% MeanRH 1 11.17 31.99 2 10.31 27.57 3 11.70 30.91 Mean 11.06 30.16 SD 0.702.30

TABLE 21 B Test B: Water Vapor Permeance for Coated Kraft Sample WaterVapor Permeance, perms Replicate 25% Mean RH 45% Mean RH Sample B7 0.742.09 Formulation: AR555 + B8 0.51 1.45 AQ401 B9 0.68 1.79 Mean 0.64 1.78SD 0.12 0.32 Water Vapor Permeance, perms Replicate 75% Mean RH 95% MeanRH B10 7.45 20.51 B11 8.19 22.86 B12 7.10 19.30 Mean 7.58 20.89 SD 0.561.81

EXAMPLE 13

Anquamine 401 is diluted with water by adding 4 weight parts water to 1weight part of Anquamine 401. The dilution is mixed with moderate shearat ambient conditions for 15 minutes to avoid formation of foam. Then, 1weight part of SoyAA-1 latex (known as EK 5-02/22) is blended with 1.25weight part of the diluted Anquamine 401. Thereafter, 3 weight parts ofAncarez AR555 is added to 2.25 weight parts of the diluted Anquamine401/SoyAA-1 latex blend. The resulting blend had a weight ratio ofAncarez AR555:Anquamine 401:Soy AA-1 latex of 3:1.25:1. The resultingblend was applied onto kraft paper sheets. Tables 22A and 22B show theresults of the ASTM E96 tests. The results are also summarized in FIG.5.

TABLE 22 A Test C: Water Vapor Permeance for Coated Kraft Sample WaterVapor Permeance, perms Replicate 25% Mean RH 45% Mean RH Sample 1 2.325.87 VOMM Formulation: 2 2.11 2.30 SoyAA-1 latex + AR555 + 3 1.67 2.00AQ401 Mean 2.03 3.39 SD 0.33 2.15 Water Vapor Permeance, perms Replicate75% Mean RH 95% Mean RH 1 7.21 10.11 2 8.28 13.52 3 8.15 10.63 Mean 7.8811.42 SD 0.59 1.84

TABLE 22 B Test D: Water Vapor Permeance for Coated Kraft Sample WaterVapor Permeance, perms Replicate 25% Mean RH 45% Mean RH Sample 1 1.293.21 VOMM Formulation: 2 0.87 2.30 SoyAA-1 latex +AR555 + 3 0.86 2.00AQ401 Mean 1.01 2.50 SD 0.25 0.63 Water Vapor Permeance, perms Replicate75% Mean RH 95% Mean RH 1 4.74 12.23 2 5.70 14.58 3 4.92 12.85 Mean 5.1213.22 SD 0.51 1.22

Comparison samples were prepared with polyethylene dispersions, PE1 andPE2. PE1 is Michem® Emulsion 93235 (a nonionic polyethylene emulsion);PE1 is Michem® Emulsion 61335 (an anionic polyethylene emulsion). ForPE1, the SoyAA-1 latex:polyether ratio was 1:1. For PE2, the SoyAA-1latex:polyether ratio was 3:2. The resulting blend was applied ontokraft paper sheets. Tables 23A and 23B show the results of the ASTM E96evaluation.

TABLE 23A Comparative Test A: Water Vapor Permeance for Coated KraftSample Water Vapor Permeance, perms Replicate 25% Mean RH 45% Mean RHSample 1 12.69 23.07 VOMM Formulation: 2 13.58 24.75 SoyAA-1 latex + PE13 11.00 19.71 Mean 12.42 22.51 SD 1.31 2.56 Water Vapor Permeance, permsReplicate 75% Mean RH 95% Mean RH 1 38.36 63.67 2 31.75 53.73 3 32.6954.53 Mean 34.27 57.31 SD 3.57 5.52

TABLE 23B Comparative Test B: Water Vapor Permeance for Coated KraftSample Water Vapor Permeance, perms Replicate 25% Mean RH 45% Mean RHSample 1 5.01 9.03 VOMM Formulation: 2 4.84 8.64 SoyAA-1 latex + PE1 34.70 8.35 Mean 4.85 8.67 SD 0.15 0.34 Water Vapor Permeance, permsReplicate 75% Mean RH 95% Mean RH 1 20.25 39.16 2 19.32 36.44 3 18.6837.49 Mean 19.42 37.70 SD 0.79 1.37

TABLE 23C Comparative Test C: Water Vapor Permeance for Coated KraftSample Water Vapor Permeance, perms Replicate 25% Mean RH 45% Mean RHSample 1 13.15 22.37 VOMM Formulation 2: 2 12.81 21.56 SoyAA-1 latex +PE2 3 11.76 20.04 Additive Mean 12.57 21.32 SD 0.72 1.18 Water VaporPermeance, perms Replicate 75% Mean RH 95% Mean RH 1 36.68 56.32 2 36.4156.54 3 33.70 52.63 Mean 35.59 55.17 SD 1.65 2.20

TABLE 23D Comparative Test D: Water Vapor Permeance for Coated KraftSample Water Vapor Permeance, perms Replicate 25% Mean RH 45% Mean RHSample 1 8.75 15.94 VOMM Formulation 2 2 6.88 12.21 SoyAA-1 latex + PE23 6.63 11.92 Additive Mean 7.42 13.36 SD 1.16 2.24 Water VaporPermeance, perms Replicate 75% Mean RH 95% Mean RH 1 20.97 31.18 2 18.8528.54 3 17.64 27.93 Mean 19.15 29.22 SD 1.68 1.73

When introducing elements of the examples disclosed herein, the articles“a,” “an,” “the” and “said” are intended to mean that there are one ormore of the elements. The terms “comprising,” “including” and “having”are intended to be open-ended and mean that there may be additionalelements other than the listed elements. It will be recognized by theperson of ordinary skill in the art, given the benefit of thisdisclosure, that various components of the examples can be interchangedor substituted with various components in other examples.

Although certain aspects, examples and embodiments have been describedabove, it will be recognized by the person of ordinary skill in the art,given the benefit of this disclosure, that additions, substitutions,modifications, and alterations of the disclosed illustrative aspects,examples and embodiments are possible.

1. An article comprising: a substrate selected from the group consistingof cellulosic substrates, non-cellulosic substrates, and combinationsthereof; an aqueous dispersion disposed on the substrate and effectiveto provide a variable water vapor perm rating as a function of humidity,in which the water vapor perm rating is about 2 perm or less at 25%average RH, as tested by ASTM D1653; or 2 perm or less at 25% averageRH, as tested by ASTM E96, when the aqueous dispersion is cured as acoating on the substrate.
 2. The article of claim 1, in which the curedcoating is further effective to provide a water vapor perm rating ofless than or equal to 5 perms at 45% average RH as tested by ASTM D1653,or less than or equal to 5 perms at 45% average RH as tested by ASTME96.
 3. (canceled)
 4. (canceled)
 5. The article of claim 1, in which theaqueous dispersion comprises a plant oil macromonomer dispersion. 6.(canceled)
 7. (canceled)
 8. The article of claim 1, further comprising areactant added to the aqueous dispersion.
 9. (canceled)
 10. (canceled)11. The article of claim 8, in which the aqueous dispersion comprises awaterborne epoxy resin dispersion and the reactant comprises an amine.12. (canceled)
 13. The article of claim 8, further comprising at leastone filler added to the waterborne macromonomer dispersion and thereactant.
 14. The article of claim 13, further comprising astain-resistance additive in the dispersion.
 15. The article of claim 1,in which the aqueous dispersion is substantially free of polyamides. 16.An article comprising: a substrate selected from the group consisting ofcellulosic substrates, non-cellulosic substrates, and combinationsthereof; and a plant oil macromonomer dispersion disposed on thesubstrate and effective to provide a variable water vapor perm rating,as tested by ASTM D1653 or ASTM E96, when the plant oil macromonomerdispersion is cured as a coating on the substrate.
 17. The article ofclaim 16, in which the variable water perm rating is about 2 perms orless at 25% average RH, is less than or equal to 5 perms at 45% averageRH, is about 12 perms to about 24 perms at 75% average RH, and isgreater than 25 perms at 95% average RH as tested by ASTM D1653, orabout 2 perm or less at 25% average RH, is less than or equal to 5 permsat 45% average RH, is about 6 perms to about 12 perms at 75% average RH,and is greater than 11 perms at 95% average RH as tested by ASTM E96.18. (canceled)
 19. The article of claim 17, in which the plant oilmacromonomer dispersion is a vegetable oil macromonomer dispersion. 20.The article of claim 19, in which the vegetable oil macromonomerdispersion further comprises a reactant.
 21. (canceled)
 22. The articleof claim 20, further comprising a filler in the dispersion. 23.(canceled)
 24. The article of claim 22, further comprising a surfactantin the dispersion. 25-31. (canceled)
 32. The article of claim 16, inwhich the cellulosic substrate is kraft paper.
 33. (canceled)
 34. Thearticle of claim 16, further comprising a building material coupled tothe cellulosic substrate.
 35. (canceled)
 36. An article comprising: asubstrate selected from the group consisting of cellulosic substrates,non-cellulosic substrates, and combinations thereof; and a waterborneepoxy resin dispersion disposed on the substrate and effective toprovide a variable water vapor perm rating, as tested by ASTM D1653 orASTM E96, when the waterborne epoxy resin dispersion is cured as acoating on the substrate.
 37. The article of claim 36, in which thevariable water perm rating is about 2 perms or less at 25% average RH,is less than or equal to 5 perms at 45% average RH, is about 12 perms toabout 24 perms at 75% average RH, and is greater than 25 perms at 95%average RH as tested by ASTM D1653, or about 2 perm or less at 25%average RH, is less than or equal to 5 perms at 45% average RH, is about6 perms to about 12 perms at 75% average RH, and is greater than 11perms at 95% average RH as tested by ASTM E96.
 38. The article of claim3, in which the waterborne epoxy resin is a waterborne solid epoxyresin.
 39. (canceled)
 40. The article of claim 38, further comprising areactant added to the aqueous dispersion.
 41. (canceled)
 42. The articleof claim 40, further comprising a filler in the dispersion. 43.(canceled)
 44. (canceled)
 45. The article of claim 42, furthercomprising a surfactant in the dispersion. 46-54. (canceled)
 55. Thearticle of claim 46 36, further comprising a polyamide in thedispersion. 56-153. (canceled)